Soap flakes



June 25, 1929. B; w. COLTMAN 1 .778

SOAP FLAKES Original Filed Aug. 15, 1921 2 Sheets-Sheet l I M4196 w;zsqaw k/Q/a June 25, 1929. w COLTMAN 1,718,778

SOAP FLAKES Original Filed Aug. 15, 1921 2 Sheets-Sheet 2 INVENTORATTORNEY Patented June 25, 1929.

UNITED STATES PATENT OFFICE.

lBEBTR-AM WM. COLTMAN, OF CHICAGO, ILLINOIS.

SOAP FLAKES.

Original application My invention relates to soap flakes and is adivision of my copending application, Serial Number 492,214, filedAugust 15, 1921, since granted as United States Letters Patent No.1,653,390.

- An object of my invention is to provide a soap flake having voidstherein and more particularly a soap flake having a greater volume perunit of weight than that of its'ingredients before mixed.

According to my invention, a soap flake is provided which isparticularly flufl'y, quickly soluble in water and of attractiveappearance, having a characteristic crystalline voidlike thin-walledstructure which is exceedingly light and porous.

In order to apprise those skilled in the art how to practice andconstruct my invention, I shall now describe a preferred embodimentthereof, when taken in connection with the accompanying drawing, whichshows one form of structure that may be used to produce soap flakes inaccordance with my invention, other forms that may be used having beendisclosed and claimed in United States Letters Patent Nd. 1,653,390, itbeing under.- stood, however, that any of these other forms or processesmay be used with equal advantage to produce my improved form'of soapproduct.

Figure 1 illustrates apparatus which may be used to practice theinvention; and

Figure 2 is a photo-microscopic view of the product.

Referring to the drawing, liquid soap is fed into a vat 2 through asupply pipe 3 containing a supply control valve 4:. Supply pipe 3 maylead directly from the large vat wherein the necessary ingredients areprepared into soap. The solution taken from such a vat may contain anysuitable percentage of water, but if a reater percentage is desiredafter the liquid soap flows into vat 2, water or other suitable thinningfluid such as alcohol or acetone may be added. Such thinning fluid maybe supplied to vat 2 through a pipe 6 having valve 5. This fluid ismixed with the soapy solution by means of an ordinary wire stirrer 7.Stirrer 7 is carried upon a shaft 8, which is driven by any suitablemeans, as for instance by a belt 9. A hot air jacket 10 may surround themixing vat 2 to keep its contents at a certain temperature.

From vat 2, the liquid soap of reduced confiled August 15, 1921, SerialNo. 492,214, new Patent No. 1,653,390. Divided an this application filedDecember 20, 1927. Serial No.-241,361.

sistency is fed through a valve 11 into a whip p1ng vat 12, WlllCll, asshown, is of the ordinary type. The whippcr comprises simply the beltdriven shaft 13 carrying wires or rods 14, which stir and aeratethe'n'iaterial. The construction is such that the stirringinstrumentalities, i. e., wires or rods, pass through the viscid masswith a smooth cutting, as distinguished from either an ebulliting orkneading action, whereby there is obtained indefinitely repeated cuttingof the occluded air into smaller and smaller subdivisions, withcomparatively small levitation or expulsion thereof, there being aconversion of the mass into froth, lather or foam. During the aeratingstep, the liquid soap may be kept at a certain temperature, whichgreatly facilitates the action thereof, the heat being supplied by awarm air jacket 23' surrounding vat 12.

A sprayer 17 driven by a pump 15 may be used to feed the liquid soap inthe form of a mist upon a traveling surface 113, forming a thin film orpellicle of soap. This sprayer may act to divide theflow, so that thelather is discharged in a comparatively line mist, which settles uponthe traveling surface in a thin sheet. The soap, owing to its plasticand adhesive character, will remain upon the belt and will spread evenlythereover by its own action. As the belt travels along its upperhorizontal run, warm air of sufficient avidity to remove the moisture isdirected against the soap by any suitable means, as for in.-

- stance by a blower 18 and manifold 19 having any number of jets 20,from which air is emitted. By the time the soap reaches the end of thebelts horizontal run, it will be of a spongy andv friable nature, thatis, there will be a tendency for it to crumble into fine flakes as soonas it is disturbed. It is here proposed to provide such disturbance bycreating an abrupt break in the straight run of the belt. Roller 21serves this purpose, while, if so desired, an auxiliary means may beused to remove soap which persists in clinging to the belt. Thisauxiliary means is in the form of one or more blades 22, which bearlightly against the belt without wearing or destroying the same. It isto be noted that the flakes are permitted to drop practically untouchedinto receptacle 23, which prevents lumping.

It will be noted that the soap will be somewhat spongy in character andfriable, so thatit will break or crumble into flakes orparticles, whenremoved from the belt. These flakes or particles will have a definiteporous structure and contain Voids therein which render them light andflutfy, giving them greater Volume and solubility. Having voids therein,when the flakes are removed from the belt, rather thin walled cellularstructures are produced, which retain their unity as flakes orparticles, and which does not thereafter crumble into powder. A greatersurface is exposed by the thin celled walls separated by the voids, andconsequently, greater solubility is obtained. The soap product consistsof soap material which is heat dried to result in cellular or porouswalls, these walls being highly absorbent of and quickly soluble inwater. The particles of soap contain definitely formed voids withinwhereby the particles are relatively hollow and are surrounded bycellular walls, these walls appearing as small cells or poresinterconnected by smaller finely divided walls. The particles are formedas such to a large extent in the making by the processes disclosed in myparent case, it betherein being substantially surrounded by thincellular walls, said walls being sufficiently porous to render theproduct absorbent of and readily soluble in water.

2. A substantially dry soap product consisting of soap material. havingcellular or porous walls, being highly absorbent of and qu ckly solublein water, said product having voids therein surrounded by said cellularwalls to thereby present available surface area which is large relativeto the amount of soap contained therein.

3. A soap product which is light and is readily soluble in water andcomposed of soap particles which are generally of cavity 01 void formsurrounded partially by walls which are of a porosity noted particularlyby small cells or pores interconnected by smaller finely divided walls.

4. A spray processed soap product composed of generally hollow particlescharacterized by their dry thin walls notably filled with minute porouscellular-like openings.

5. A heat treated spray processed porous .soap product solidified intocharacteristic cellular component particles or bodies of void formation,so as to be large considering the amount of soap contained in eachcomponent particle or body thereby to present available surface areawhich is large relative to the amount of soap in each particle or bodywhereby each particle or body may be readily dissolved in an aqueousliquid, the said void formation being more particularly defined as.

thin walls substantially dry throughout, the thin dry walls being porousand partially onclosing cavity-like voids in the soap product.

6. A soap product formed of substantially small bodies having voidstherein substantially surrounded by thin walls, the surface of saidwalls exhibiting minute cellular formation.

7fComponent particles of a porous soap product which are characterizedby their thin dry porous cellular walls and with voids thereinsubstantially surrounded by said cellular walls and of such size as tocause the particles to be large considering the amount of soap containedtherein.

In Witness whereof, I have hereunto subscribed my name.

BERTRAM WM. COLTMAN.

